CT-S-ENG D379+

CCaatteerr ppii ll llaarrService Manual

D379, D398D,D399,G379, G398 & G399

Engines

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORSARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Serv

ice

Man

ual

,

r'

SERVICE MANUAL for

CATERPILLAR

0399 ~ G399 039a 0379

G39a G379

ENGINES

SERIAL NUMBERS 35BI-UP 49CI-UP 91BI-UP .

66B2049-UP 67B920-UP

68B1616-UP 698824-UP

73B511-UP

728264-UP

..... ~.

1 ."

Group 10.1

Page 2

14A-5

ENGINE ROT A TION

SAE Standard Rotation engine (counterclockwise as viewed from the flywheel end) is marked with a transfer on the flywheel housing. SAE Opposite Rotation engine (clockwise as viewed from the fly­wheel end) is also marked with a transfer on the flywheel housing.

1 ARD RDTATIDN~ .A.E. STANDARDI-------:::'

(lgnlcuS'n) -10·15·16·11-12·13·14·7-8 11-2-3-10-7-6 ·6 7M9576-6

~ SAE STANDARD ROTATIO ~ CROTACION S.A.E. STANDAR

FIRING OIOill IIgnlGonl

V.16 1.2.11_12_3 ...... 'Iji.l0_IS_16_S-6-13-14-7

:-9030_B-J'I~ =====.1 ~SAE OPPOSITE ROTATION--""'-­L........--CROTACION S.A.E. OPUESTA} ~

FIRING OROU IIgn ••• onl

V·16 1_12_1I_4_3_1()"9_16_15 6_5 14_13_8_72

2Nl148

ENGINE ROTATION TRANSFERS I-Transfer used on SAE Standard Rotation Natural Gas and Diesel (8 and 12 cylinder) engines and Diesel 16 cylinder engines. 2-Transfer used on SAE opposite Rota­tion Natural Gas and Diesel (8 and 12 cylinder) engines and Diesel 16 cylinder engines. 3-Transfer used on SAE Standard Rotation Natural Gas 16 Cylinder engines. 4-Transfer used on SAE Opposite Rotation Natural Gas

16 cylinder engines.

ISSUED 2-69

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SERVICE MANUAL GENERAL INSTRUCTIONS

Group 30 Page I

These instructions will be helpful in following the instructions in the Service Manual. In analyzing a system malfunction, use this systematic procedure to locate and correct the problem.

I. Determine problem.

2. List possible causes.

3. Devise checks.

4. Conduct checks in logical order to determine cause.

5. Consider remaining service life against cost of parts and labor.

6. Make necessary repair.

7. Recheck.

SYMBOLS

Throughout this Service Manual, symbols are used on the illustrations to point out parts which are to be removed or disconnected. These removals or disconnections are indicated by the following code:

o Remove • Disconnect

The part to be removed or disconnected is point­ed out by a number in the symbol and this number corresponds to the part discription listed in the cap­tion copy beneath the picture. The disconnect arrOw points as close as possible to point of disconnection.

SAFETY AND WORKMANSInP SUGGESTIONS

Your safety and that of others is always the number one consideration when working around machines. Safety is a matter of thoroughly under­standing the job to be done and the application of good common sense. It is not just a matter of "do's" and "don'ts".

Always show proper respect for weight. Do not at­tempt to lift heavy parts when a hoist should be used. Never leave heavy parts in an unstable position. When raising a portion of a machine, be sure the machine is blocked securely at front and rear. The weight should be supported by blocks rather than lifting equipment.

When using a hoist, follow the recommendations outlined in the manual. Fabricate and use the illus­trated lifting devices in conjunction with the hoist to achieve the proper balance of the assemblies being lifted and to assure safe handling.

CLEANLINESS

The most important single item m preserving the long life of the machine is to keep dirt out of vital working parts. Precautions have been taken to safe­guard against this. Enclosed compartments, seals and fillers have been provided to keep the supply

of air, fuel and lubricants clean. It is important that these safeguards be maintained.

Whenever hydraulic, fuel, lubricating oil or air lines are disconnected, clean the point of discon­nection as well as the adjacent area. As soon as the disconnection is made, cap, plug or tape the line or opening to prevent entry of foreign material. The same recommendations for cleaning and covering apply when access covers or inspection plates are removed.

Clean and inspect all parts. Be.sure all passages and holes are open. Cover all parts to keep them clean. Be sure parts are clean when they are in­stalled. Leave new parts in their containers until ready for assembly.

SPECIF1CATIONS

The manual SPECIFICATIONS sections contain di­mensions for new parts and a suggested guide for amount of wear that might normally be considered a reasonable figure to use in determining when to replace parts. These wear dimensions are shown after the description, "permissible clearance". The specifications are provided to help determine when new parts should be installed. This information should not be regarded as the only factor in determ­ining when to replace parts. Past performance should be the governing factor for part replacement. Even though parts are worn they still may be satisfactory. The remaining service life of these parts must be con­sidered when deciding if parts should be replaced. If a machine is disassembled for reconditioning, it is well to replace parts not completely worn out if the remaining service life is deemed short.

REMOVAL AND INSTALLATION

CO R REel

Correct and incorrect method of lifting component.

Unless otherwise specified, all removals should be accomplished using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other and as near perpendicular as possible to the top of the object being lifted.

When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt

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Page 2 SERVICE MANUAL GENERAL INSTRUCTIONS

diminishes as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only have stress in tension. A length of pipe and a washer can be used, as shown, to help relieve these stresses on eyebolts.

Forged eyebolt support.

Some removals require the use of lifting fixtures to obtain proper balance and provide safe handling.

Use a hoist to remove heavy parts. The weights of some components are given in their respective sections of the manual.

If a part resists removal. check to be certain all nuts and bolts have been removed and that an adjacent part is not interfering.

DISASSEMBLY AND ASSEMBLY

When assembling a machine, complete each step in turn. Do not partially assemble one part and start assembling some other part. Make all ajustments as recommended. Always check the job after it is com­pleted to see nothing has been overlooked.

Recheck the various adjustments by operating the machine before returning it to the job.

PRESSING PARTS

When pressing one part into another, use 9M3710 Anti-Seize Compound or a molybdenum disulfide base compound to lubricate the mating surfaces.

Assemble tapered parts dry. Before assembling parts with tapered splines, be sure the splines are clean, dry and free from burrs. Position the parts together by hand to mesh the splines before apply­ing pressure.

Parts which are fitted together with tapered splines are always very tight. If they are not tight. inspect the tapered splines and discard the part if the splines are worn.

BOLTS AND BOLT TORQUE

Use bolts of the correct length. A bolt which is too long may "bottom" before the head is tight against the part it is to hold. The threads can be damaged when a "long" bolt is removed.

If a bolt is too short, there may not be enough . threads engaged to hold the part securely.

Unless reference is made in the copy to the topic, SPECIFICATIONS, the standard torque values listed in the chart should be used for standard heat-treated bolts and studs and steel nuts when ass~mbling Caterpillar Equipment.

GENERAL TIGHTENING TORQUE

inches mm lb. ft. mkg

Bolts and Nuts

% 6,35 9±3 1,24±0,4 5 7,94 18±5 2,5±0,7 II>

% 9,53 32±5 4,4±0,7 _7_ 11,11 50±10 6,9±1,4 16

112 12,70 75±10 10,4±1,4 _9_ 14,29 110±1--5 15,2±2,0 16

% 15,88 150±20 20,7±2,8 % 19,05 265±35 36,6±4,8 "'a 22,23 420±60 58,1 ±8,3

1 25,40 640±80 88,5±11,1 1% 28,58 800±100 110,6±13,8 11/4 31,75 1000±120 138±16,6 1% 34,93 1200±150 166±20,7 lV2 38,10 1500±200 207±27,7

Taperlock Studs

V4 6,35 5±2 0,69±0,3 5 7,94 10±3 1,4±0,4 H % 9,53 20±3 2,8±0,4 ll> 11,11 30±5 4,1 ±0,7 1f2 12,70 40±5 5,5±0,7

191> 14,29 60±10 8,3±1,4 % 15,88 75±10 10,4±1,4 % 19,05 11 O± 1 5 15,2±2,0 % 22,23 170±20 23,5±2,8

1 25,40 260:::,:30 35,9±4,1 IVa 28,58 320:::':30 44,2±4,1 IV4 31,75 400:::,:40 55±5,5 1% 34,93 480:::':40 66±5,5 1112 38,10 550±50 76:::':7

Hydraulic Valve Body Bolts and Nuts 5 7,94 13±2 1,8±0,3 II> % 9,53 24±2 3,3±0,3 7 11,11 39±2 5,4±0,3 H

V2 12,70 60.:± 3 8,3±0,4 % 15,88 118±4 16,3±0,5

T95559-1

LOCKS

Lockwashers, flat metal locks or cotter pins are used to lock nuts and bolts.

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GENERAL INSTRUCTIONS

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Flat metal locks must be installed properly to be effective. Bend one end of the lock around the edge of the part. Bend the other end against one flat sur­face of the nut or bolt head.

Always install new locks in compartments which house moving parts.

When installing lockwashers on housings made of aluminum, use a flat washer between the lock­washer and the housing.

SHARP BEN17 ! r I a

[1 PJ rr T~ T60687 CORRECT CORRECT INCORRECT

Correct and incorrect methods of installing flat metal locks.

CORRECT INCORRECT

T63488

Correct and incorrect method for lock positioning and bending.

LINES AND WIRES

When removing or disconnecting a group of lines or wires, tag each one to assure proper assembly.

LUBRICATION

Where applicable, fill the compartments of the components serviced with the amount, type and grade of lubricant recommended in the Operation and Maintenance Instructions.

RUST PREVENTIVE COMPOUND

Clean the rust preventive compound from all machined surfaces of new parts before installing them.

SHIMS

When shims are removed, tie them together and identify them as to location. Keep shims clean and !lot until they are reinstalled.

BEARINGS

Anti-Friction Bearings

When an anti-friction bearing is removed, cover it to keep out dirt and abrasives. Wash bearings in nonflammable cleaning solution and allow them to drain dry. The bearing may be dried with com­pressed air but do not spin the bearing.

Discard the bearings if the races and balls or rollers are pitted, scored or burned. If the bearing is serviceable, coat it with oil and wrap it in clean paper. Do not unwrap new bearipgs until time of installation.

The life of an anti-friction bearing will be short­ened if not properly lubricated. Dirt in an anti-friction bearing can cause the bearing to lock resulting in the shaft turning in the inner race or the outer race turning within the cage.

/

T59296

Effect of dirt in bearing.

Double Row, Tapered Roller

Double row, tapered roller bearings are precision fit during manufacture and the components are not interchangeable. The cups, cones and spacers are usually etched with the same serial number and let­ter designator.·· If no letter designators are found,. wire the components together to assure correct in­stallation. Reusable bearing components should be installed in their original positions.

Heating Bearings

Bearings which require expansion for installation should be heated in oil not to exceed 250 0 F. (121 0

C.). When more than one part is heated to aid in assembly, they must be allowed to cool and then pressed together again. Parts often separate as they cool and shrink.

Installation

Lubricate new or used bearings before installa­tion. Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain ac­curate preloading. When installing a bearing, spacer

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Page 4 SERVICE MANUAL GENERAL INSTRUCTIONS

or washer against a shoulder on a shaft, be sure the chamfered side is toward the shoulder.

INCORRECT

16061& CORRECT

Correct and incorrect installation of spacer.

When pressing bearings into a retainer or bore, apply pressure to the outer race. If the bearing is pressed on the shaft, apply pressure on the inner race.

Preload

Preload is an initial load placed on the bearing at the time of assembly. Whether a taper roller bear­ing should have preload could depend on any of several conditions: rigidity of the housings and shaft, bearing spread, speed of operation, etc.

The only certain way to determine what a bear­ing requires, preload or end clearance, is to consult the disassembly and assembly topic pertaining to that bearing.

Care should be exercised in applying preload. Misapplication of preload to bearings requiring end clearance can result in bearing failure.

Sleeve Bearings

Do not install sleeve bearings with a hammer. Use a press if possible and be sure to apply the pressure directly in line with the bore. If it is necessary to drive on a bearing use a bearing driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part.

GASKETS

Be sure the holes in the gaskets correspond with the lubricant passages in the mating parts. If it is necessary to make gaskets, select stock of the proper type and thickness. Be S'llre to cut holes in the right places. Blank gaskets can cause serious damage.

When removed, always install new cylinder head and manifold gaskets using recommended gasket compound on head gaskets to allow ,miform sealing.

BRAKE LININGS

Replace brake linings before they have worn enough to permit the rivet heads to can toe! and score the brake drums.

BATTERIES

Clean batteries by scrubbing with a solution of baking soda and water. Rinse with clear water. After cleaning, dry thoroughly and coat terminals and connections with an anti-corrosion compound or grease.

If a machine is to be stored or not used for a long period of time, the batteries should be removed. Store them in a warm, dry place, preferably on wooden shelves. Never store on concrete. A small charge should be introduced periodically t9 keep the specific gravity rating at recommended level.

SEALS

Duo-Cone Floating Seals

Floating ring seals have highly finished surfaces and are held .together by toric seaiing rings. The flexibility of the toric sealing rings makes the floating ring seals self aligning and compensates for wear on the metal faces.

During disassembly, tape the metal floating ring seals together so they will be kept in matched sets. Always install the metal floating ring seals in pairs; that is, two new seals together or two seals that have previously run together. Never reinstall a used toric sealing ring.

Handle all parts with care to avoid nicks. File smooth any parts, other than the sealing faces, that have nicks that may make assembly difficult or questionable. Wash off all dirt accumulation from used parts. Use a wire brush to clean dirt or rust from the bore of the seal retainers to assure they are clean and smooth. Remove all oil or the protec­tive coating from floating ring seals and retainers with a nonflammable cleaning solvent. Be sure the ramp on the retainers and on the floating ring seals are dry.

Check the ramps for tool marks and nicks. On used parts, remove dirt or rust deposits from the ramps. Smooth the surface with emery cloth.

1 2 3 4

~ T87T99

An example of a correct installation 01 a metal floating ring seal and toric sealing ring. The illustration shows the dimension (I) to be checked. the metal floating ring seal (2), the rubber to ric sealing ring (3) and the toric sealing ring retainer (4). The dimension must be uniform around the entire circumference of the floating ring seal. Check the dimension at 90 0 intervals.

IA-S SERVICE MANUAL

GENERAL INSTRUCTIONS

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Install new toric sealing rings or floating ring seals. Seat the toric sealing rings uniformly in the relief of the ring seal. Be sUre the toric sealing ring is not twisted. It must set straight against the lip which keeps it from falling off the floating ring seal.

Duo-Cone floating seal installation tools are avail­able for various size seals.

SEAL INSTALLING TOOL SELECTION CHART

~UO-CONE METAL TORIC

SEAL RING SEAL

SEALING INSTALLER SEAL GROUP

RING

4K60.19 4KI74 4K173 158966 7M481 7M480 7M475 9M5143 5M1176 4M2621 2M344 8M7911 5M8647 IM9012 IM9011 8M9395 (15576) 5MII77 4M659 4M660 8M7912 5M7294 4M735 4M736 8M7913 404510 404471 404472 154320 2M2858 lM3098 IM3097 5M2196 IM8747 8H2229 8H2262 5M2158 lM8746 8H2230 8H2265 5M2160 IM8748 8H2231 6HI309 5M2162

455001 8< 751527 455002 & 751528 354672 554275 5K5288 5K5126 5K5129 554276 5Kl078 5KI069 5KI075 258027 408960 408959 4D3472 753128

If an installer tool is not used, install the toric sealing ring and floating ring seal as an assembly by pressing on the toric sealing ring. Use finger pres­sure only. Be sure the toric sealing ring is seated uniformly in the recess of both the floating ring seal and the retainer. Make sure it sets in the bore straight and against the lip that keeps it from falling out of the retainer. Do not use a screwdriver or stick to assemble the torie sealing ring in the retainer. Use finger pressure only.

Before assembling floating ring seals together, wipe faces of seals with lint-free tissue to remove any foreign material and fingerprints. Place one drop of oil on the cleaning tissue and coat the seal­ing surfaces of the seals. Be careful to prevent any oil from contacting the toric sealing ring or its mating surfaces.

Duo-Cone floating seals installed with metal floating ring seal (2) and toric sealing ring (3) properly positioned.

Lip-Type Rubber Seals

3

Lubricate the lips of lip-type rubber seals before installation. Use the some type lubricant in which

the seal will be operating. Do not use grease on any seal except a grease seal.

The main parts of a lip-type seal are the case, sealing element, and garter spring. The picture be­low illustrates the construction of a simple lip-type seal. The cross section at the top shows the terms "heel" and "toe" used to identify the sides of a single element seaL With few exceptions, the toe of an oil seal with one lip is next to the lubticant that is sealed. Some seals have a second auxiliary lip, which does not carry a garter spring. Use the spring­loaded lip to orient the installation. of. such seals.

HEEL {~ ~ } TOE

~ SEAl! NG ELEMENT

~ ~~:::5::::T EDGE-----o!-

TRIM SURFACE - _____ ~~

GARTER SPRING GROOVE

GARTER SPRING

BOND AREA ./"Wf..----CASE

T87198

Lip-type seal construction.

If, during installation, the seal lip must pass over a shaft that has splines, a keyway, rough surface or a sharp edge, the lip can easily be damaged. Shim stock or other such material can be formed around the area to provide a smooth surface over which to slide the seal.

HYDRAULIC SYSTEMS

Cleanliness Dirt and like contaminants in a hydraulic system

affect operation." and will result in serious damage to the system components. Dirty hydraulic systems are a major cause of machine failures.

Keep the system clean:

.... When removing components of a hydraulic sys­tem cover all openings in both the component and the machine .

. . . . If evidence of metal or rubber' particles are found in the hydraulic sfsi~m, flush the entire system .

. . Disassemble and assemble hydraulic compo­nents on a clean surface. Clean all metal parts in a nonflammable cleaning fluid. Then lubri­cate all components to aid in assembly.

Safety

Before servicing any hydraulic system, NEUTRAL­IZE THE HYDRAULIC PRESSURE.

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PageS SERVICE MANUAL GENERAL INSTRUCTIONS

PROCEDURE:

1. Place all implements (bucket, ripper, dozer, etc.) on the ground. (In some instances a removal procedure may require the implement to be blocked in a certain position. Consult the re­moval and installation topics pertaining to that implement) .

2. With the engine shut-off, move all the control levers to all positions to insure there is no pres­sure in the system.

3. Place all control levers in HOLD position.

When attached hydraulic equipment is removed from a machine which will continue to be used, the hydraulic system lines must be securely blocked. High pressure protective covers are available. The following chart lists the protective covers for vari­ous size hydraulic hoses. One O-ring seal is required with each protective cover.

APPROXIMATE HOSE SIZE PRO - TWO O-RING SPLIT

TECTTVE SEAL BOLT FLANGE INCHES MILLIMETERS

COVER FLANGE 0.0. J.D. 0.0. LD.

1.00 .50 25,4 12,7 5H4017 5F7054 SF6804 1 H5278

1.06 .62 26.9 15,7 857668 4J8996 -- 6K3Z53

1.25 .75 31,7 19,0 SH4Dt3 SF1678 5F2046 2K190

1.50 1.00 38.1 25,4 SH4019 4F7391 SF2442 lH330S 2.00 1.25 50,8 31,7 5H40Z0 4F7952 -- 3H3667 2.25 1,50 57.1 38,1 2J2668 7F8267 -- 3H4330

T93ZOf, A

Do not use the thin sheet metal covers designed for shipping and storage. These covers can rupture when high pressure is applied.

Sealing Elements

Inspect all sealing elements (O-rings, gaskets, etc.) when disassembling =d assembling the hy­draulic system components. Install new elements if necessary.

Hydraulic Lines

When installing metal tubes, tighten all bolts finger-tight. Then, in this order, tighten the bolts at the rigid end, the adjustable end, and the mounting brackets. After the tubes are mounted, install the hoses. Connect both ends of the hose with all bolts finger-tight. Position the hose so it does not rub the machine or another hose and has a minimum of bending =d twisting. Tighten bolts in both cou­plings.

Due to manufacturing methods there is a natural curvature to a hydraulic hose. The hose should be installed so any bend is with this curvature. In case of replacement hoses with angled-stem, reusable fittings. the hose curvature must be taken into con-

sideration when assembling =d positioning the angled stems.

After the hoses are installed, follow this proce-. dure: With the diesel engine running, move the ap­

propriate control levers to move the implement to every possible position. Observe the hoses during the cycle. Then lower the implement to the ground. Shut off the diesel engine =d eliminate =y twist­ing, rubbing =d/or excessive drooping of hoses by rotating the stern of the hoses.

Hydraulic Fittings

Fitting Bodies with Straight Threads =d O-ring Seals

This type of fitting is used in several applications The tube end of the body will vary in design de­pending upon the application. However, the instal­lation procedure of the fitting body into its mating boss will be the same. If the tube end of the fitting body is as illustrated (either elbow or straight body) a presetting procedure is necessary to assemble the sleeve onto the tube before connecting the tube to end. See the topic ASSEMBLY OF SLEEVES ONTO TUBES, TYPE A.

1

T88381

2

3

,. __ --4

5

6

Typical example of an elbow body assembly. Parts are: I-End of fitting body (connects to tube). 2-Fitting body. 3-Locknut. 4-Backup washer. S-O-ring seal. S-End of

fitting (screws into mating boss).

1. Place the nut, washer and seal as far back on the fitting body as possible. Hold the compo­nents in this position and screw the fitting into its boss until the washer just contacts the face of the boss.

2. Place the fitting assembly in its correct angu­lar position by turning the body out (counter­clockwise). a maximum of 359 0 . Tighten the nut finger-tight.

NOTE

If the fittmo is a connector (straight fitting), the hex on the body takes the place of the nut. In­stall this type fitting by lightening the hex against the face of the boss.

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SERVICE MANUAL GENERAL INSTRUCTIONS

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3. Install the assembled tube onto the tube end of the body, finger-tight. Tighten the nut position­ing the body. Then tighten the nut on the tube assembly.

Assembly of Sleeves onto Tubes

Type A

It is necessary to preset this type of sleeve onto the' tube before the tube assembly is installed on the fitting body.

T88382

Typical example of a sleeve-type fitting. Parts are: I-Tube. 2-Nut. 3-Sleeve. 4-Presetting tooL S-Shoulder of tool (4).

1. Lubricate the sleeve and the threads on pre­setting tool and nut.

NOTE

Presetting tools are commerically available; however, the fitting body can be used in place of a presetting tool. If the fitting body is used, the body should be removed from the machine to permit satisfactory presetting.

2. Place the nut on the tube with the threaded end of the nut toward the end of the tube.

3. Place the sleeve onto the tube so the short­tapered heavy end faces the presetting tool as illustrated.

4. Bottom tube end against shoulder of tool.

5. Assemble the nut to the tool finger-tight. Then tighten the nut until the threads on the tool are no longer visible.

6. Remove the tube from the presetting tool. Check to be certain sleeve does not move longitudinally. (The sleeve can rotate on the tube)

7. When the tube assembly is assembled onto the fitting body, tighten the nut until the threads on the body are no longer visible. Refer to the topic FITTING BODIES WITH STRAIGHT THREADS AND O-RING SEALS for the installa­tion of the fitting bodies.

Type B

1. Place the nut and sleeve onto the tube. Install the sleeve so the thick end faces away from the body.

2. Install the insert into the tube.

Typical example of sleeve and insert·type fitting. Parts are: I-Nut. 2-Tube. 3-Sleeve. 4-Insert. 5-Fitting body.

3. Bottom the tube and insert in the body as illustrated.

4. Tighten the nut 1 liz turns past finger-tight.

TypeC

T88384

Typical example of a shear-type fitting. Parts are: I-Nut. 2-Sleeve. 3-Fitting body. 4-Tube.

With the nut and sleeve installed loosely in the body, install the tube through the nut and sleeve until the end of the tube is seated against the shoulder in the fitting body.

Grip the tube firmly to prevent twisting or turn­ing and tighten nut until a slight "give" or de­creased resistance is felt. The "give" indicates that the sleeve has been sheared from the nut. Tighten the nut an additional lliz turns. It is not necessary to tighten the nut all the way down.

Hydraulic Valves

Examine all valves, valve bores and valve seats for nicks, burrs and/or scratches. (Rough spots may be removed with a crocus cloth or fine emery

. - ~

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PageS SERVICE MANUAL GENERAL INSTRUCTIONS

cloth.) All valves which operate in bores must slide freely in their bores. Be certain all passages are clean and open.

Check all springs to be certain they meet the values listed in the SPECIFICATIONS.

On control valve spools having bolt-retained centering or return springs, the bolt should be re­moved while the valve spool is in the valve body. This procedure will prevent spool distortion and possible damage to the spool lands .

Typical example of removing bolt.

Cylinders

Rod End or Head End

The "rod end" of a cylinder is that end that has the rod extending.

The "head end" is the other end of the cylinder - the blind end.

The rod end line directs oil to the rod end of the cylinder to retract the rod. The head end line directs oil to the head end of the cylinder to extend the rod.

T91388

This is a cross section of a hydraulic cylinder. Identified are: I-Rod end. 2-Head end.

Installation of Solid Seal Assemblies on Pistons

Each solid seal assembly consists of a solid, rub­ber, inner expansion ring and a solid, plastic, outer seal. Since these seals are continuous rings (no split joint), special tools and procedures are re­quired for installation.

The tools needed to install the outer seals of the piston seal assemblies are: one 4S9181 Expander assembly, one 4S9446 Clamp Assembly (two clamp assemblies are required on the larger diameter pis-

tons). and one seal compressor. Measure the diame­ter of the piston to select the correct seal compressor. See the COMPRESSOR SELECTION CHART for the seal compressor to be used.

T8UIO

Solid seal inslallation lools. Paris identified are: 1-459181 Expander Assembly. Z-Seal compressor. 3-4S9446

Clamp Assembly.

COMPRESSOR SELECTION CHART

PISTON DIAMETER SEAL COMPRESSOR

(IN INCHES) (IN MILLIMETERS) PART (NO.)

1.50 - 3.00 38,1 - 76,2 95289 3.00 - 3.25 76,2 - 82,S 459447 3.50 - 3.75 88,9 - 95,2 459448 4.00 - 4.25 101,6 - 107,9 459449 4.50 - 4.75 114,3-120,6 459450 5.00 - 5.25 127,0 - 133,3 459451 5.50 - 5.75 139,7 - 146,0 459452 6.00 - 6.25 152,4 - 158,3 459453 6.50 - 6.75 165,0 - 171,4 459454 7.00 - 7.25 1n,8 - 184,1 459455* 8.00 - 8.25 203,2 - 209,5 459456* 9.25 - 9.50 234,9 - 241,3 459457*

10.25 - 10.50 260,3 - 266,7 952419*

*TWO 459446 CLAMP ASSEMBLIES REQUIRED.

T93676-A

Compressors are marked for nominal ranges shown in the chart. The actual usable range can be calculated by reducing the low figure 1/16 in. (1,5 mm) and increasing the high figure 3/16 in. (4,7 mm).

4 5

TIl 9 81

Solid seal assemblies installed on piston. Parts identified are: 4-Wear ring. 5-Solid, plastic outer seals. 6-Piston.

7-Solid. rubber. inner expansion rings.

IA-5 SERVICE MANUAL

GENERAL INSTRUCTIONS

Group 30

Page 9

1. For ease of seal installation, remove the wear ring.

2. Install the inner expansion rings on the piston.

3. Measure the diameter of the piston to determine the diameter to which the seal must be ex­panded. The outer seals of the seal assemblies must be expanded to a diameter slightly larger than the diameter of piston to allow the seal to be placed over the piston. Be careful not to over­expand the seals or they can be ruined.

NOTE

The bars of the expander are graduated, repre­senting piston diameters. If the seal can be slipped off the expander when the inside face of the movable block is at point (A) (indicated piston diameter) the seal is expanded suffi­ciently.

4. Place a seal on the expander~ Turn the crank on the expander until the inside face of the movable block is slightly past point (A). Then return to point (A). Rotate the seal 900 on the expander and expand again. Check to see if the seal will slip off the expander If not, repeat the procedure, expanding the seal farther each time, until seal will slip off the expander when block is returned to point (A).

5. Lubricate the outer seals and place them on the piston. Install and lubricate the wear ring.

6. Select the applicable compressor from the COM­PRESSOR SELECTION CHART. Install the clamp on the compressor. Place the compressor loosely over the outer seals. Place the compressor on the piston so the rolled side of the compressor will be facing the cylinder when the piston is in­stalled in the cylinder.

This shows the seal on the expander. lllustrated are: 1-4S9181 Expander Assembly. A-Indicated piston

diameter.

7. Slowly turn the handle on the clamp and force the seals into their grooves. Be certain the seals are being seated in their grooves as they are being compressed.

The tools illustrated compressing seals are: 2-Seal com­pressor. 3-4S9446 Clamp Assem])!y.

This shows the installation of the piston into the cylinder.

8. Place the piston assembly into the cylinder bore as illustrated; be certain the piston is square in the bore.

9. Drive on the piston rod until the entire piston assembly is in the cylinder bore. Remove the clamp and the compressor.

10. Install the bolts securing the cylinder head to the cylinder with the piston rod fully extended. Tighten the bolts to the torque value in the SPECIFICATIONS.

Pumps

The direction of pump rotation, clockwise (CW) or counterclockwise (CCW), is the direction the pump turns when viewed from the drive shaft end. Refer to the SPECIFICATIONS for the rotation of a particular pump.

After assembling any pump, lubricate it thor­oughly. After assembly, the pump must rotate freely by hand.

Assembly of Insert Vane-type Pumps

The insert vane-type pump capacity and direction of rotation will vary with different applications. The assembly procedure however will be the same.

Before disassembling a pump, mark the pump bqdy and cover to insure correct assembly with re­spect to port relationship.

D399 ENGINE (35BI-UP, 9IBI-UP)

TABLE OF CONTENTS

Section-

Index ...................... ' ....... , ................. . 14A-IO Specifications ........................................ . 14A-1O Cooling System (Radiator) .............................. . 14A-IO Cooling System (Heat Exchanger-cooled) ................. _ .. 14A-IO Cooling System (Keel Cooling) 91Bl-up .................... . 14A-IO Water Temperature Regulators ........................... . 14A-IO Expansion Tank ............................ ' .......... . 14A-IO Fan Group 35Bl-up ....................... _ ........... . 14A-IO Fresh Water Pump .................................... _ . 14A-IO Raw Water Pump ................ _ ............ _ ......... . 14A-IO Radiator 35Bl-up ..................................... . 14A-IO Lubricating System .................................... . 14A-IO Oil Pan ............................................. . 14A-IO Oil Pump (Single-section) ............................... . 14A-IO Oil Cooler ................... " ................ " .... . 14A-IO Oil Filters ......................................... .. . 14A-IO Sump Pump .......................................... . l4A·IO Fuel System ......................................... . 14A-IO Fuel Supply Equipment ................................ . 14A-IO Fuel Injection Equipment ............................... . 14A-IO Safety Shut-off Control ................................. . 14A-IO Governor (Hydra-mechanical) ............................ . 14A-IO Fuel Pump and Governor Drive ........................... . 14A-IO Air Induction and Exhaust System ........................ . 14A-IO Turbocharger (Schwitzer 4HD854 and 4HF857) .............. . 3A-IO Turbocharger (Schwitzer 4MD) ........................... . lOA-IO Cylinder Heads ....................................... . 14A-IO Valves and Valve Mechanism ............................. . 14A-IO Vibration Damper ..................................... . 14A-IO Timing Gears ......................................... . 14A·IO Front Accessory Drive .................................. . 14A-IO Basic Block Components ................................ . 14A-IO

(Includes-Crankshaft Removal-Cylinder Liners, Pistons, Rings and Connecting Rods Disassembly and Assembly)

Flywheel and Flywheel Housing .......................... . 14A-IO

14A-l0

Group

30.1 40.1 70.1 80.1 90.1

100.1 120.1 130 140.1 150 160 170.1 180.1 190.2 200.1 210.1 220 230 240.2 250.1 251 260.3 265.3 270.4 271.1 271 280.3 290.1 300 320 330 345

390

Group 20.1 Page 1

A Accessory Drive Gear:

Front .............................. ~ .... . Rear .................................... .

Adjustments: Carburetor and Regulator ................... . Front Accessory Drive ...................... . Fuel Pump Lifters ......................... .

Governor Governor Drive Gear ....................... . Rear Accessory Drive (Timing Gears) .......... .

Aftercooler ..........•................•..•.. Air Cleaner ..............•.................. Air Induction and Exhaust System .............. .

Altitude Operation ..•........................

B

Group

330 320

270.5 330 250.1 250.1 260.3 265.3 320 270.4 270.4 270.4 270.5 271 271 271.1

Balancer, Engine ............................. 380 Base, Engine:

Oil Lines Connections ..... . . . . . . . . . . . . . . . . .. 180 180.1

Pressure Regulating Valve .................... 190.1 190.2

Seal ................... . . . . . . . . . . . . . . . ... 180 180.1

Basic Block Components . . . . . . . . . . . . . . . . . . . . . .. 345 Bearings:

Connecting Rod . . . . . . . . . . . . . . . . • . . . . . . . . . .. 345 Main .................................... 345 Piston Pin ................................ 345

Bolt, Nut and TaperJock Stud Torque. . . . . . . . . . . . . 40.1 Bypass:

Fuel ...........•......................... 240.2 Valve, Oil . . . . . . . . . . . . . • . . . . . . . .. . . . . . . . ... 210.1

c Camshaft 320 Camshaft Gear . . . . . . . . . . . . . . . . • • . . . . . . . . . . . .. 320 Carburetors ...............•.......•......•.• 270.5 Olambers, Precombustion • . • . . . . . . . . . . . . • . . . . .. 280.3 Cleaner, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 270.4 Cleaning:

Engine Valves ............................. 290.1 Fuel Injection Valve ........................ 250.1 Pistons .................................. . Radiator ................................ . Turbocharger ............................. .

Clearances and Tolerances ., ................... . Compression Release Mechanism ................ . Connecting Rod Bearings ...................... . Cooler, Oil (Water·Cooled) .................... .

Cooling System

Counterclockwise and Clockwise Differences:

245 160 271 271.1

40.1 290.1

345 200 200.1

70.1 80.1 90.1

Camshaft ............. . . . . . .. ............ 320 Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 345 Fuel Injection Camshaft .................... . Fuel Pump Lifter Settings ................... . Rear Accessory Drive (Timing Gears) .......... .

250.1 250.1 320

14A-l0

ENGINE INDEX

Group 30.1 Page 1

Page

1 2 5 7

1 2 2 4 5 4

1 2 2

3 3

1 1

4 6 4

3 2

1 2 5

4 1

6 6

5 4

3

6 4 4 3

Group

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 345 Cylinder Heads .............................. 280.1.-

280.3 Cylinder Liners 345

D

Page

6 1 1 4

Damper, Vibration ...................••.•.•.•. Directors, Water ..............•.....•.........

300 - 1 280.1 - 2 280.3 '2

Drive: Front Accessory .......................... . Fuel Pump and Governor ................. , .. . Governor .......................... : •..... Magneto .................................. . Rear Accessory (Timing Gears) ............... .

330 265.3 265.4 266 320

Safety Shut-off ...................•........ 265.3 3 Tachometer Drive 265.3 3

E Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.1 Exhaust Bypass System . . . . . . . . . . . . . . . . . . . . . . .. 270.5 Exhaust Manifold ............................ 270.4 Exhaust Valve Expansion Tank ............................. .

F

Fan Filters:

Fuel .................................... . Oil ..................................... .

flow of Coolant ............................ .

flow of Fuel .......•.............•........•. flow of Lubricating Oil ....................... . flywheel and Flywheel Housing ................ . Front Accessory Drive ........•................

Lubrication .............................. . Fuel:

Bypass ......•. '.' ........................ . Filter .........• -......................... . Pump and Governor Drive ................... . Pump Yoke and Plunger Inspection ............ . Ratio Control .............•............... Injection:

290.1 120 120.1

130

240.1 210.1

70.1 80.1 90.1

230 170.1 390 330 170.1

240.2 240.2 265.3 250.1 260.3

Camshaft .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 250.1 Equipment. . . . . . . . . • . . • . . . . . . . . . . . . . . . .. 250.1 Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 250.1 Pump Camshaft, Timing ................... 250.1 Pump Housing. . . . . . . . . . . . . . . . . . • . . . . . . .. 250.1

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . .. 170.1 Pump Lifter Setting. . . . . . . . . . . . . . . . . . . . . .. 250.1 Valves ................................. 250.1

System, Diesel ...... . . . . . . . . . . . . . . . . . . . . . .. 230 Priming, Pump ............................ , 240.2 Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 240.2

G

Gauge: Fuel .................................... . Oil

230 170.1

4 2 1 1

2

1 2

3 2 1

8 8

4 1 1

9 3

1 7 1

1

2

14A·10 Group 30.1 Page 2 ENGINE

INDEX

Gear: Accessory Drive:

Front ................................. . Rear (Timing Gears) ..................... .

Camshaft ................•................ Crankshaft .........•..........•...•....... Fuel Pump and Governor Drive " ...........•.. Ring Gear, Flywheel ....................... . Timing .................. " .•..•...•.........

Governor:

Adjustments (Diesel) •...•........••.•.•..... Adjustments (Gas Engine) ..............•••••. Drive ......•......•..•....•....•..•••....

Lubrication ....•...•........•••••......... Seals •....•......••.......•••.•...•......

Guides, Valve .......•........................

H Heads, Cylinder

Housing: Flywheel Fuel Injection Pump ................•......• Fulll Injection Pump and Governor Drive ....... . Front Accessory Drive-...................... . Rear Accessory Drive (Timing Gears) •..•.......

Ignition System ..............•..•.......•....

Injection Equipment, Fuel ........•............• Inlet:

Manifold .................•..•............ Valve ................••.....•....•.......

Inspection:

Group Page

330 1 320 1 320 1 345 6 320 1 390 1 320 1 330 - 2

260.3 5 260.3 6 265.3 1 265.4 1 260.3 1 260.3 290.1 3

280.1 1 280.3 1

390 1 250.1 3 265.3 330 1 320

259.2 1 259.3 250.1

270.4 - 4 290.1 2

Fuel Injection Valve .•••••..•..•..•......... 250.1 1 Fuel Pump Lifter Yoke and Pump Plunger ..•...• 250.1 - 8 Valve. . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . .. 290.1 - 2

L Lifters:

Fuel Pump Setting. . . . . . . . . . . . . • • . . • . . . . . . .. 250.1 7 Valve. . . . . . . . . . • • . • . . . • . • .• . . . . . . • . . . . . .• 290.1 3

Line Pressure Regulator. . . . . . . . . . . . . • . • • . . . . . •. 269 270.5

Liners, Cylinder . . . . . . . . . . . . . . . . . • . . . . . . . . . . .. 345 Lubricating System. . . . . . . . . . . . . . . . . • . . . . . . . .• 170.1

Pre·Lub System. . . . . . . . . . . . . . . . . . . . • . . . • . .. 170.1 Lubrication:

Front Accessory Drive .•..................... Fuel Injection Pump Housing and Governor ..... . Main Oil Pump ............................ .

Oil Pressure .............................. . Piston and Rings .......................... . Prelube System .... " ...................... . Pressure Regulating Valve ................... .

Rear Accessory Drive (Timing Gear) ........... . Scavenge Oil Pump ........................ " Turbocharger Lubrication Valve .. " ........... .

170.1 170.1 190.1 190.2 170.1 345 170.1 190.1 190.2 170.1 190.1 170.1 210.1 271 271.1

3 4 1

2

2

1

2 2 4 2 3 3 2 2 2 2

Group Page

M

Magneto Drive . . . . . . . . . • . . • . . • . . . . . . . . . . . . . .. 266 Main Bearings .••.........•.••••............. 345 Main Suction Bell ....•...••••.•.....•...•...• 180

180.1 Manifolds:

Exhaust.. . .. . . . . . • . .. • . . . . . . . . • . . . . . . . . •. 270.4 Inlet. . . .. . . •. . . • .• . . . . . . . . . . . .. . . . . . . . . .. 270.4

o Oil:

Bypass Valve ••... . . . . . . . . . • . . . . • • . . . . • . . .. 210.1 Cooler (Water Cooied) . . . • • . • . . . . . . . . . . . . . . .. 200

200.1 Filters ....••...•.....•..••..............• 210.1

180 Pan .............•...••....•............. 180.1 Pressure •............•••.••..•••••........ Pressure Shut·off ....•.•.•.•............•... Pump, Main .•..•...•......................

Pump, Scavenge ...•.......••••............. Operating Difficulties:

Engine Coolant Overheating ....•.............

Engine Fuel System ........................ . Engine Lubrication System •...............•.. Fuel Injection Equipment ...............•.... Valves and Valve Mechanism ..............•...

Overflow, Sealed Pressure •••..................• Overheating, Coolant •....•....................

Overspeed Shut·off ...••.....•.....•....•.....

p

Pan, Oil Pistons •.......•........•..•..............•. Piston Pin Bearing ....••...•......••.......... Piston Rings •••......••...•.••••••...•.•...•• Precombustion Chambers ..•..••...••.•..•.•..• Prelube System Testing .......••.•.........•... Pressure, Oil ..•...•.........• ;" ......•.•..•••. Pressure Regulating Cap ...••.•.•..•............

Pressure Regulating Valve (Main Oil Pump) ........ .

Pump: Fuel:

Injection .•.............••...•.......... Priming ...................•.•.......... Transfer .......•........................

Oil: Main ...............•.............•....

Scavenge .............................. . Sump ................................... . Water:

Fresh ................................. . Raw .................................. .

R

170.1 251 190.1 190.2 190.1

70.1 80.1 90.1

230 170.1 250.1 290.1 160

70.1 80.1 90.1

251

180.1 345 345 345 280.3 170.1 170.1 120 120.1 160 190.1 190.2

250.1 240.2 240.2

190.1 190.2 190.1 220

140.1 150

6

1

2 4

2 1

1

1

2

1 2

1 2 1

1

1 2

1

3

4 4 4 2 4 2 1 1 2 3 3

1 2

Rack Setting 260.3 - 5

ENGINE INDEX

14A-10 Group 30.1 Page 3

Group Page Group Page

Radiator ..........•........................ Rear Accessory Drive (Timing Gears) ............ .

Lubrication ..............................• Regulator, Line Pressure ...................... . Regulators, Water Temperature ................. . Release, Compression ........................ . Ring Gear, Flywheel ......................... . Rings, Piston .•.....•.....................•.. Rocker Arms, Valve .......................... . Rod, Connecting .......................•...•. Rotators, Valve ...............•.........•...• Run-out:

Crankshaft Oil Thrower .........•...•........ Flywheel ................................ . Flywheel Housing .........................•

S

160 320 170.1 269 100.1 290.1 390 345 290.1 345 290.1

345 390 390

Safety Shut-off Control ...................... " 251

Scavenge Pump, Oil ......................•.... Seal Replacement, Water ........••.............

Sealed Pressure Overflow (Radiator Cap) .......... .

Seals:

265.3 190.1 140.1 150 120 120.1 160

Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 260.3 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 271

Water Pump .............................. .

Setting, Fuel Pump Lifter ..................... .

Setting, Rack ............................... . Spark Plug Adapters ......................... .

271.1 140.1 150 250.1 250.1 260.3 280.1

Specifications ............................... 40.1 Springs, Valve .........................•..... 290.1 Suction Bell. . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 180 Sump Pump . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . .. 220

T Tachometer Drive Tank, Expansion ............................ .

Temperature Regulators, Water ................. . Thrower, Crankshaft Oil ............•.......... Timing:

Front Accessory Gears ...................... .

265.3 120 120.1 100.1 345

330

1 2

4

4 1 4

6 2

3 2 2 3 2

2

2 2 3 5 7

5 2 1 2

3

1

6

2

Fuel Injection Pump Camshaft Gears ................................... . Magneto (Spark Gap) ....................... . Magneto (Solid State) ...................... . Valves .................................. .

Torque ......•................•............. Transfer Pump, Fuel ......................... . Transformer, Ignition ........................ .

Thrbocharger ....•........... '.' ....•.........

Thrbocharger Lubrication Valve ...•..•........•. Thrbocharger and Lines ....................... .

v Valve:

Bypass, Fuel Bypass, Oil ............................... . Exhaust Bypass ........................... . Fuel Injection ............................ . Inlet and Exhaust ................. ;; ....... .

250.1 3200-259.2 259.3 290.1 40.1

240.2 259.2 259.3 271 271.1 210.1 270.4

240.2 210.1 270.5 250.1 290.1

Inspection and Reconditioning ................ 290.1 Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 290.1 Pressure Relief, Main Oil Pump ................ 190.1

190.2 Rocker Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 290.1 Rotators ................................ . Seat Specifications ......................... . Spring Specifications ....................... . Stem Guides ............................. . Timing .................................. . Thrbocharger Lubrication ................... .

Valves and Valve Mechanism ................... .

290.1 40.1 40.1

290.1 290.1 210.1 290.1

Vibration Damper ............................ 300

Water: Directors

Pump: Fresh

w

280.1 280.3

140.1 Raw ........ ; .......................... 150 Seal Replacement ....................... .

Temperature Regulators .................... . Temperature Shut-off Control ................ .

140.1 150 100.1 251

9

I 2 3

9 5 1 1 2

3 2

4

I

3 3 3

I

3 3 2

2 2

2

3

Group 40.1 Page 12

14A-10 ENGINE SPECI FICA nONS

CYLINDER LINER

(1) Bore in liner ••.••..•••. 6.250-6.252 in. (158,75-158,80 mm)

Maximum bore (worn) measured near top of ring travel ....•................... 6.260 in. (159,004 mm)

(2) Thickness of flange •... , .•.•• 504-.506 in. (12,80-12,85 mm)

Counterbore depth in block ••• .498-.500 in. (12,65-12,70 mm)

Maximum permissible counterbore depth ••.. 545 in. (13,84 mm)

OIL FILTER

(1) Diameter of valve. . • .. 1.4965-1.4975 in. (38,011-38,036 mm)

(2) 3H2757 Spring for bypass valve:

Length under test force. . . . • . . • . . . . . • • . . . .• 2 in. (50,8 mm)

Test force ..••.•.•.••....... 32-37.5 Ibs. (14,51-17,01 kg)

Free length after test. • . . . . . • • . . . • . . . . • . •. 4 in. (101,6 mm)

Outside diameter ......•......•....... 1.148 in. (29,16 mm)

(3) Bore in housing ••.•.. 1.4995-1.5005 in. (38,087-38,113 mm)

FRONT ACCESSORY DRIVE

Auxiliary Drive upper left turns counterclockwise (view from front) at 1.92 times engine speed.

(1) Water pump drive:

Turns clockwise (view from front) at 1.92 times engine speed

Diamete r of shaft beari ng journal. . . . . • . . . . . . . . .. 1.245-1.246 in. (31,52-31,65 mm I

Bore in water pump shaft bearing ................ 1.248-1.249 in. (31,62-31,65 mm)

Maximum permissible clearance between shaft and bearing .......................... 008 in. (0.203 mm)

TBB321

SAE Standard Rotation Engine Illustrated

NOTE-FOR TORQUE VALUES NOT INDICATED, REFER TO FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

2

14A-IO ENGINE

Group 270.4

Page 1 AIR INDUCTION AND EXHAUST SYSTEM

~ EXHAUST GAS

t~m INLET AIR

E@] COMPRESSED AIR

I::::::::::J WATER ..........

T954Z9

Am INDUCTION AND EHAUST SYSTEM I-Exhaust manifolds. 2-Right cylinder bank. 3-Diffuser plate. 4-Right turbocharger im­peller. S-Exhaust elbow. 6-Left cylinder bank. 7-Turbocharger turbine wheels. 8-Left

turbocharger impeller. 9-Aftercooler.

OPERATION This engine incorporates two turbochargers. The

engine is cross-blown, that is, the right turbocharger furnishes air to the left cylinder bank (6) and the left turbocharger furnishes air to right cylinder bank (2).

Variation in engine load and fuel injected results in changes in speed that the turbine wheels and im­pellers rotate.

When the turbocharger compresses the inlet air for the engine cylinders, the temperature of the air increases. A water cooled aftercooler (9), installed between the turbochargers and the air inlet mani­folds to cylinder banks (2) and (6) will cool and condense the compressed air from the turbochargers. Cooler compressed air has more oxygen, thus more fuel can be injected. When more oxygen is present, more fuel is burned and engine power is increased.

A cast in diffuser plate (3) in the center of exhaust elbow (5) keeps the exhaust from each turbocharger separated to reduce exhaust back pressure.

TURBOCHARGER REMOVAL

NOTE

At assembly coat mating surfaces of housing and hose with 5H2471 Adhesive before tighten­ing clamp screw (4).

PREPARING TO REMOVE TURBOCHARGER_ I-Bolt. 2-0il inlet line. 3-0illine. 4-Clamp screw. 5-0il

return line. 6-Bolts (four). 7-Bolts (four).

4

Remove bolts (1) and (7) and loosen clamp screw (4) then move the air cleaner away from the turbo­charger.

Remove bolts (6) and loosen clamp screw (11) and remove the turbocharger. At the time of installation